System and Method for Arranging Objects in an Operating Room in Preparation for Surgical Procedures

ABSTRACT

Systems and methods for arranging objects in an operating room in preparation for a surgical procedure. The objects are arranged based on surgical procedure information provided to a guidance station. The surgical procedure information dictates the desired placement of the objects. Placement of the objects is then guided according to their desired placement using one or more tracking elements.

RELATED APPLICATIONS

This application is a divisional of U.S. nonprovisional patentapplication Ser. No. 15/591,343 filed on May 10, 2017, which claims thebenefit of U.S. nonprovisional patent application Ser. No. 14/203,663,filed on Mar. 11, 2014, which claims benefit of U.S. Provisional PatentApplication No. 61/779,725, filed on Mar. 13, 2013, the entire contentsof which are hereby incorporated by reference.

TECHNICAL FIELD

The present invention relates generally to a system and method forarranging objects in an operating room in preparation for a surgicalprocedure.

BACKGROUND

Before starting a surgical procedure, many objects need to be properlyarranged in the operating room. Such objects include equipment, thepatient, surgical personnel, instruments, and the like. Properarrangement of these objects in the operating room, before the procedurebegins, helps to ensure that the surgical procedure proceeds withoutunnecessary delays. Traditionally, objects are arranged according towritten protocols that may include operating room layouts and writteninstructions associated with the particular procedure being performed.

In some surgical procedures, navigation equipment such as sensingdevices (e.g., tracking cameras, magnetic field sensors, etc.) andtracking devices require arrangement before the procedure starts.Navigation systems employ such navigation equipment to assist users inlocating objects. For instance, navigation systems assist surgeons inprecisely placing surgical instruments relative to a patient's anatomy.Surgeries in which navigation systems are used include neurosurgery andorthopedic surgery. Typically, the instrument and the anatomy aretracked together with their relative movement shown on a display.

Navigation systems may employ light signals, sound waves, magneticfields, RF signals, etc. in order to track the position and/ororientation of objects. Tracking devices are attached to the objectsbeing tracked. A localizer, which includes the sensing devices,cooperates with the tracking devices to determine a position of thetracking devices, and ultimately to determine a position and/ororientation of the objects. The navigation system monitors movement ofthe objects via the tracking devices.

Many navigation systems rely on an unobstructed line-of-sight betweenthe tracking devices and sensing devices. When the line-of-sight isobstructed, signals being transmitted from the tracking devices are notreceived by the sensing devices. As a result, errors can occur.Typically, in this situation, navigation is discontinued and errormessages are conveyed to the user until the line-of-sight returns or thesystem is reset. This can cause delays to surgical procedures. In othertypes of navigation systems, such as those that rely on sensing magneticfields, errors can also occur with respect to placement of the trackingand/or sensing devices. For example, metal in the magnetic field cancause inaccuracies in determining the position and/orientation ofobjects being tracked.

As a result, there is a need in the art for systems and methods toassist in arranging the tracking devices and/or sensing devices to helpreduce possible errors. There is also a need in the art to use suchsystems and methods to arrange other objects in the operating room basedon the particular procedure to be performed.

SUMMARY

A system for arranging a mobile cart of a robotic system in an operatingroom according to surgical procedure information is provided. The systemincludes a tracking device, a guidance station, and a localizerconfigured to track the tracking device of the robotic system todetermine a current placement of the mobile cart. The guidance stationis coupled to the localizer and configured to receive the surgicalprocedure information, evaluate the surgical procedure information, andto determine a desired placement of the mobile cart of the roboticsystem in the operating room based on the evaluation of the surgicalprocedure information. Additionally, the system includes a displayconfigured to display visual representations of the current placementand the desired placement of the mobile cart to guide a user on manualplacement of the mobile cart in the operating room. Additionally, theguidance station is configured to guide placement of the robotic systemin the operating room by displaying representations of the currentplacement and the desired placement of the robotic system.

One advantage of these embodiments is to facilitate arranging objects inthe operating room in an efficient manner and based on the particularprocedure to be performed so that the objects are placed in desiredlocations for that particular procedure.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention will be readily appreciated as thesame becomes better understood by reference to the following detaileddescription when considered in connection with the accompanying drawingswherein:

FIG. 1 is a perspective view of a guidance station being used inconjunction with a robotic manipulator;

FIG. 2 is a schematic view of the guidance station, tracking devices,pointer, and machining station;

FIG. 3 is a flow diagram of steps carried out to create a pre-operativeplan and load the pre-operative plan into the system;

FIG. 4 is a flow diagram of steps carried out by the guidance station;

FIG. 5 is a flow diagram of steps carried out by the guidance station toassist in arranging objects in an operating room;

FIG. 5A is an illustration of a screen shot from an OR Setup softwaremodule providing instructions on placement of a camera unit;

FIG. 5B is an illustration of an alternative screen shot from the ORSetup software module providing instructions on placement of the cameraunit;

FIG. 5C is an illustration of a screen shot from the OR Setup softwaremodule providing instructions on placement of a patient;

FIG. 5D is an illustration of a screen shot from the OR Setup softwaremodule providing instructions on placement of trackers;

FIG. 5E is an illustration of an alternative screen shot from the ORSetup software module providing instructions on placement of trackers;

FIG. 6 is an overhead view of a sample right-handed operating roomlayout;

FIG. 7 is an overhead view of a sample left-handed operating roomlayout;

FIG. 8 is a flow diagram of steps carried out to place trackers relativeto a patient;

FIG. 9 is a flow diagram of steps carried out to place the machiningstation; and

FIG. 9A is an illustration of a screen shot from the OR Setup softwaremodule providing instructions on placement of a machining station.

DETAILED DESCRIPTION

Systems and methods are disclosed for arranging objects in an operatingroom. Referring to FIGS. 1 and 2, in one embodiment, the system includesa guidance station 20 and tracking elements associated with variousobjects. The tracking elements are capable of communicating with theguidance station 20 to track the objects. Procedure information isprovided to the guidance station 20. The procedure information may comefrom a pre-operative surgical plan and/or be provided intra-operatively.Based on the procedure information (e.g., identification of anatomybeing treated, type of procedure—such as hip replacement surgery ortotal or partial knee replacement surgery, implant types/sizes, patientinformation, surgeon preferences, etc.), the guidance station 20performs the steps of determining a desired placement of the objects andguiding surgical personnel to place the objects according to the desiredplacement. One advantage of this system and method is to reduce setuptime in the operating room and improve the efficiency of surgeries.

In FIG. 1, the guidance station 20 is shown in an operating room of amedical facility. The guidance station 20 is set up to track movement ofthe various objects in the operating room. Such objects include, forexample, a surgical instrument 22, a femur F, and a tibia T. Theguidance station 20 tracks these objects for purposes of displayingtheir relative positions and orientations to the surgeon and, in somecases, for purposes of controlling or constraining movement of thesurgical instrument 22 relative to a predefined path or anatomicalboundary. The guidance station 20 also assists in arranging theseobjects and other objects in the operating room prior to the start of asurgical procedure and/or intra-operatively, as will be discussedfurther below.

The guidance station 20 includes a computer cart assembly 24 that housesa navigation computer 26, or other type of control unit. A navigationinterface is in operative communication with the navigation computer 26.The navigation interface includes a first display 28 adapted to besituated outside of the sterile field and a second display 29 adapted tobe situated inside the sterile field. The displays 28, 29 are adjustablymounted to the computer cart assembly 24. First and second input devices30, 32 such as a keyboard and mouse can be used to input informationinto the navigation computer 26 or otherwise select/control certainaspects of the navigation computer 26. Other input devices arecontemplated including a touch screen (not shown) or voice-activation.

A localizer 34 communicates with the navigation computer 26. In theembodiment shown, the localizer 34 is an optical localizer and includesa camera unit 36 (also referred to as a sensing device). The camera unit36 has an outer casing 38 that houses one or more optical positionsensors 40. In some embodiments at least two optical sensors 40 areemployed, preferably three or more. The optical sensors 40 may be threeseparate charge-coupled devices (CCD). In one embodiment three,one-dimensional CCDs are employed. It should be appreciated that inother embodiments, separate camera units, each with a separate CCD, ortwo or more CCDs, could also be arranged around the operating room. TheCCDs detect infrared (IR) signals.

Camera unit 36 is mounted on an adjustable arm to position the opticalsensors 40 with a field of view of the below discussed trackers that,ideally, is free from obstructions. The adjustable arm allows adjustmentof the camera unit 36 in at least one degree of freedom and, in someembodiments, in two or more degrees of freedom.

The camera unit 36 includes a camera controller 42 in communication withthe optical sensors 40 to receive signals from the optical sensors 40.The camera controller 42 communicates with the navigation computer 26through either a wired or wireless connection (not shown). One suchconnection may be an IEEE 1394 interface, which is a serial businterface standard for high-speed communications and isochronousreal-time data transfer. The connection could also use a companyspecific protocol. In other embodiments, the optical sensors 40communicate directly with the navigation computer 26.

Position and orientation signals and/or data are transmitted to thenavigation computer 26 for purposes of tracking the objects. Thedisplays 28, 29 and camera unit 36 may be like those described in U.S.Pat. No. 7,725,162 to Malackowski, et al. issued on May 25, 2010,entitled “Surgery System”, hereby incorporated by reference.

The navigation computer 26 can be a personal computer or laptopcomputer. Navigation computer 26 has the displays 28, 29, centralprocessing unit (CPU) and/or other processors, memory (not shown), andstorage (not shown). The navigation computer 26 is loaded with softwareas described below. The software converts the signals/data received fromthe camera unit 36 into data representative of the position andorientation of the objects being tracked.

Guidance station 20 communicates with a plurality of tracking devices44, 46, 48, also referred to herein as trackers. In the illustratedembodiment, one tracker 44 is firmly affixed to the femur F of thepatient and another tracker 46 is firmly affixed to the tibia T of thepatient. Trackers 44, 46 are firmly affixed to sections of bone.Trackers 44, 46 may be attached to the femur F and tibia T in the mannershown in U.S. Pat. No. 7,725,162, hereby incorporated by reference.Trackers 44, 46 could also be mounted like those shown in U.S.Provisional Patent Application No. 61/753,219, filed on Jan. 16, 2013,entitled, “Tracking Devices and Navigation Systems and Methods for UseThereof”, hereby incorporated by reference herein. In additionalembodiments, a tracker is attached to the patella (not shown) to track aposition and orientation of the patella. In yet further embodiments, thetrackers 44, 46 could be mounted to other tissue types or parts of theanatomy.

An instrument tracker 48 is rigidly attached to the surgical instrument22. The instrument tracker 48 may be integrated into the surgicalinstrument 22 during manufacture or may be separately mounted to thesurgical instrument 22 in preparation for the surgical procedure. Theworking end of the surgical instrument 22, which is being tracked byvirtue of the instrument tracker 48, may be a rotating bur, electricalablation device, or the like.

The trackers 44, 46, 48 can be battery powered with an internal batteryor may have leads to receive power through the navigation computer 26,which, like the camera unit 36, preferably receives external power.

In the embodiment shown, the surgical instrument 22 is an end effectorof a machining station 56. Such an arrangement is shown in U.S.Provisional Patent Application No. 61/679,258, entitled, “SurgicalManipulator Capable of Controlling a Surgical Instrument in either aSemi-Autonomous Mode or a Manual, Boundary Constrained Mode”, thedisclosure of which is hereby incorporated by reference. A separatetracker (not shown) may be attached to a mobile cart 57 of the machiningstation 56 to track movement of the cart 57. Alternatively, throughjoint position sensors (not shown) such as position encoders, theguidance station 20 is able to determine a position of the cart 57 basedon the position and orientation of the instrument tracker 48 and owingto the rigid connection of the instrument tracker 48 relative to themachining station 56.

The optical sensors 40 of the localizer 34 receive light signals fromthe trackers 44, 46, 48. In the illustrated embodiment, the trackers 44,46, 48 are active trackers. In this embodiment, each tracker 44, 46, 48has at least three active tracking elements or markers for transmittinglight signals to the optical sensors 40. The active markers can be, forexample, light emitting diodes or LEDs 50 transmitting light, such asinfrared light. The optical sensors 40 preferably have sampling rates of100 Hz or more, more preferably 300 Hz or more, and most preferably 500Hz or more. In some embodiments, the optical sensors 40 have samplingrates of 8000 Hz. The sampling rate is the rate at which the opticalsensors 40 receive light signals from sequentially fired LEDs 50. Insome embodiments, the light signals from the LEDs 50 are fired atdifferent rates for each tracker 44, 46, 48.

Referring to FIG. 2, each of the LEDs 50 are connected to a trackercontroller 62 located in a housing (not shown) of the associated tracker44, 46, 48 that transmits/receives data to/from the navigation computer26. In one embodiment, the tracker controllers 62 transmit data on theorder of several Megabytes/second through wired connections with thenavigation computer 26. In other embodiments, a wireless connection maybe used. In these embodiments, the navigation computer 26 has atransceiver (not shown) to receive the data from the tracker controller62.

In other embodiments, the trackers 44, 46, 48 may have passive markers(not shown), such as reflectors that reflect light emitted from thecamera unit 36. The reflected light is then received by the opticalsensors 40. Active and passive tracking elements are well known in theart.

The navigation computer 26 includes a navigation processor 52. Thecamera unit 36 receives optical signals from the LEDs 50 of the trackers44, 46, 48 and outputs to the processor 52 signals relating to theposition of the LEDs 50 of the trackers 44, 46, 48 relative to thelocalizer 34. Based on the received optical signals, navigationprocessor 52 generates data indicating the relative positions andorientations of the trackers 44, 46, 48 relative to the localizer 34. Insome embodiments, the trackers 44, 46, 48 also include a gyroscopesensor 60 and accelerometer 70, such as the trackers shown in U.S.Provisional Patent Application No. 61/753,219, filed on Jan. 16, 2013,entitled, “Tracking Devices and Navigation Systems and Methods for UseThereof”, hereby incorporated by reference.

It should be understood that the navigation processor 52 could includeone or more processors to control operation of the navigation computer26. The processors can be any type of microprocessor or multi-processorsystem. The term processor is not intended to limit the scope of theinvention to a single processor.

Based on the positions of the LEDs 50 and previously loaded datarelating to the patient's anatomy and the surgical instrument 22,navigation processor 52 determines the position and orientation of thesurgical instrument 22 relative to the tissue (e.g., femur F and tibiaT) against which the working end is to be applied. The previously loadeddata includes data associated with pre-operative images, including MRIimages, CT scans, etc. taken before the surgical procedure. Thepreviously loaded data also includes geometric relationships between theworking end of the surgical instrument 22 and the LEDs 50 on instrumenttracker 48. Using well known navigation techniques for registration andcoordinate system transformation, the patient's anatomy and the workingend of the surgical instrument 22 can be registered into a coordinatereference frame of the localizer 34 so that the working end and theanatomy can be tracked together using the LEDs 50.

In some embodiments, navigation processor 52 forwards position and/ororientation data to a manipulator controller 54. The manipulatorcontroller 54 can then use the data to control the machining station 56as described in U.S. Provisional Patent Application No. 61/679,258,entitled, “Surgical Manipulator Capable of Controlling a SurgicalInstrument in either a Semi-Autonomous Mode or a Manual, BoundaryConstrained Mode,” the disclosure of which is hereby incorporated byreference.

The navigation processor 52 also generates image signals that indicatethe relative position of the surgical instrument working end to thesurgical site. These image signals are applied to the displays 28, 29.Displays 28, 29, based on these signals, generate images that allow thesurgeon and surgical personnel to view the relative position of thesurgical instrument working end to the surgical site. The displays, 28,29, as discussed above, may include a touch screen or other input/outputdevice that allows entry of commands.

Referring to FIG. 2, a localization engine 100 is a software module thatcan be considered part of the guidance station 20. Components of thelocalization engine 100 run on navigation processor 52. In some versionsof the invention, the localization engine 100 may run on the manipulatorcontroller 54.

Localization engine 100 receives as inputs the optically-based signalsfrom the camera controller 42 and, in some embodiments, thenon-optically based signals from the tracker controller 62. Based onthese signals, localization engine 100 determines the pose of thetrackers 44, 46, 48 in the localizer coordinate system. The localizationengine 100 forwards the signals representative of the poses of trackers44, 46, 48 to a coordinate transformer 102. Coordinate transformer 102is a navigation system software module that runs on navigation processor52. Coordinate transformer 102 references the data that defines therelationship between the pre-operative images of the patient and thepatient trackers 44, 46. Coordinate transformer 102 also stores the dataindicating the pose of the working end of the surgical instrumentrelative to the instrument tracker 48.

The coordinate transformer 102 then generates data indicating theposition and orientation of the working end of the surgical instrument22 relative to the tissue (e.g., bone) against which the instrumentworking end is applied. Image signals representative of these data areforwarded to displays 28, 29 enabling the surgeon and surgical personnelto view this information. To avoid interruption of this data, theline-of-sight between the trackers 44, 46, 48 and the sensors 40 is tobe maintained. If there are obstructions to the line-of-sight, thenerrors may occur.

The guidance station 20 is configured to assist with the pre-surgeryand/or intra-operative placement of objects, such as the trackers 44,46, 48, used in the operating room during a surgical procedure. Theguidance station 20 provides instructions on the arrangement of theobjects to facilitate procedural efficiency and to reduce possibleobstructions to navigation during the surgical procedure. Other objectsthat may be arranged according to instructions from the guidance station20 may include, but are not limited to, the patient, the machiningstation 56, surgical personnel, the camera unit 36, other instruments,equipment, or stations, and the like. The instructions provided by theguidance station 20 may be based on procedure information such as thetype of procedure being performed, preferences of the surgeon performingthe procedure, implant types/sizes, patient information, and otherfactors.

Referring to FIG. 3, in the embodiment shown, the instructions from theguidance station 20 are provided based on the pre-operative plan. Thepre-operative plan is created in step 101. Pre-operative plans areprescribed by surgeons for each patient and describe in detail the typeof procedure being performed, the target anatomy that is being treated,the types, sizes, and/or shapes of implants (if any) that are beingimplanted, surgeon preferences, and other information.

Creation of the pre-operative plan includes several steps. First, thepatient is diagnosed to determine the appropriate treatment for thepatient. Next, the surgeon prescribes the treatment. In the embodimentshown, the treatment is a total knee replacement. The surgeon'sprescription includes the imaging of the patient's bones, i.e., thefemur and tibia using MRI, CT scan, etc. Once imaging of the bones iscomplete, the images are used to prepare or select an appropriate designof a total knee implant. The design can also be based on a kinematicstudy of the patient performed in the operating room (OR) immediatelyprior to the surgery.

The design includes the type of implant, the size/shape of the implant,and the location on the bones to which the implant is to be fixed (whichincludes identifying the tissue to be removed to receive the implant).This information may be stored in electronic form in a computer readableformat such as a text file, image file, or the like. The design may beprepared or selected by the surgeon or by a third party. Once the designof the knee implant is determined, the surgeon reviews the design, andif acceptable, approves the design and the surgical procedure isscheduled. Once the surgical procedure is scheduled, the operating roomis prepared for the surgery, which includes arranging the objects basedon the pre-operative plan.

In other embodiments, the objects are arranged based on procedureinformation determined at the time of the surgery, i.e., notpre-operatively.

The pre-operative plan is stored on the guidance station 20 in step 103.The pre-operative plan may be stored in the navigation computer 26 usinga wired or wireless internet connection to the navigation computer 26,by flash memory device, or the like. In some cases, the surgeon or hisor her designee transfers the encrypted pre-operative plan (includingdesign information) to the guidance station 20, via hospital or surgicalcenter secure local area network (Ethernet), secure USB flash drive, orsecure wireless (Wi-Fi) connection. In some embodiments, thepre-operative plan is created using the guidance station 20.

Referring to FIG. 4, once the procedure information (e.g., informationfrom pre-operative plan) is stored in the navigation computer 26, an ORSetup module 109 (see FIG. 2) can be used to begin setting up theobjects in the operating room. The OR Setup module 109 is a softwaremodule that runs on navigation computer 26. The surgical personnel canoperate the OR Setup module 109 using the user interface and displays28, 29 of the guidance station 20. When using the OR Setup module 109,the surgical personnel first load the procedure information (e.g.,pre-operative plan) into the OR Setup module 109. When loaded, certaininformation is made available to the OR Setup module 109.

The OR Setup module 109 determines a prescribed arrangement of objectsbased on the procedure information in step 104. The prescribedarrangement of objects can be determined by looking for certaininformation loaded into the OR Setup module 109 and matching theinformation to one of a plurality of prescribed arrangements listed in alook-up table. The look-up table is stored on the navigation computer26. For instance, the information loaded may identify the type ofprocedure as “TOTAL KNEE—LEFT”. The OR Setup module 109 is programmed toselect a prescribed arrangement of objects based on this type ofprocedure by finding in the look-up table the specific arrangementassociated with “TOTAL KNEE—LEFT”.

Prescribed arrangements include overhead layouts such as those shown inFIGS. 6 and 7. These overhead layouts may be stored in the navigationcomputer 26 as image files or other file types. Alternatively, theoverhead layouts may be part of the pre-operative plan and/or loadedalong with the procedure information into the OR Setup module 109.Different layouts may be associated with different procedure types.Different layouts may also be associated with different surgeonpreferences. For example, the layout shown in FIG. 6 is for aright-handed surgeon, while the layout shown in FIG. 7 is for aleft-handed surgeon.

Once the prescribed arrangement is determined, the guidance station 20provides instructions to arrange the objects accordingly in step 105.Such instructions can be carried out in the order shown in FIG. 5. Otherorders of these instructions are also contemplated.

In step 108, the guidance station 20 displays the overhead layoutdetermined by the OR Setup module. The overhead layout is shown on thedisplays 28, 29. The overhead layout provides the surgical personnelwith instructions on the gross placement of the objects including theguidance station 20, the patient and operating table, the machiningstation 56, the surgeon, nurses, and other objects. As described furtherbelow, more precise positioning of trackers 44, 46 and the machiningstation 56 is also navigationally guided by the guidance station 20.

Now that the overhead layout is shown, the surgical personnel can movethe guidance station 20 into its indicated position on the overheadlayout. Once in position, the method moves to step 110 which directsplacement of the camera unit 36. Transition to step 110 may requireinput from the surgical personnel, such as selecting “OK” or “DONE” onthe displays 28, 29 with an input device to indicate to the OR Setupmodule 109 that the guidance station 20 is in position.

The camera unit 36 is adjustable about at least one degree of freedomand, in some cases, about two or more degrees of freedom. The guidancestation 20, through the OR Setup module 109, instructs the surgicalpersonnel on how to position the camera unit 36. This instruction mayinclude written instructions present on displays 28, 29 to adjust thecamera unit 36 to a predetermined height or a predetermine anglerelative to ground. Referring to FIG. 5A, the instruction for placementof the camera unit 36 may include visual guidance showing an exemplarysetup for the camera unit 36. Once the camera unit 36 is properlyplaced, transition to step 112 may require input from the surgicalpersonnel, such as selecting “OK” or “DONE” on the displays 28, 29 withan input device to indicate to the OR Setup module 109 that the cameraunit 36 is in position.

In some embodiments, joints of the arms for moving the camera unit 36may have position encoders that can be read by the navigation computer26 and used to dynamically track movement of the camera unit 36 relativeto the ground based on known geometric relationships between the cartassembly 24, ground, adjustment arms, and camera unit 36. In this case,referring to FIG. 5B, visual guidance on the displays 28, 29 can includeshowing a representation of the current position of the camera unit 36(shown in hidden lines) relative to a representation of the desiredposition of the camera unit 36. The representation of the currentposition dynamically moves on the displays 28, 29 toward or away fromthe representation of the desired position as the user adjusts aposition of the camera unit 36. The OR Setup module 109 can transmitimages to the displays 28, 29 showing the direction of required movementto reach the desired position, such as the arrow shown in FIG. 5B. Oncethe current position of the camera unit 36 is within a predefinedtolerance of the desired position, the OR Setup module 109 indicatesthat the desired position has been reached and moves to Step 112.

The patient is brought into the operating room on the operating table instep 112. The patient, in the case of a total knee replacement, iseither brought in under anesthesia or anesthesia is administered in theoperating room. The surgical staff may also secure the leg of interestin a leg holder, and drape the patient and equipment. One such legholder is shown in U.S. patent application Ser. No. 13/554,010,entitled, “Multi-position Limb Holder”, published as U.S. PatentApplication Publication No. 2013/0019883, hereby incorporated byreference.

Instructions on the placement of the patient may include writteninstructions on the displays 28, 29 regarding positioning of theoperating table relative to the guidance station 20. Such instructionsmay include establishing a desired distance between the computer cartassembly 24 and the operating table or aligning a particular side of theoperating table with respect to the camera unit 36. The instruction forplacement of the patient may include visual guidance showing anexemplary setup for the patient relative to the camera unit 36.

In some embodiments, a video camera (not shown) is attached to thecamera unit 36. The video camera is oriented such that a field of viewof the camera unit 36 can be associated with the field of view of thevideo camera. In other words, the two fields of view may be matched orotherwise correlated such that if an object (e.g., LEDs 50) can be seenin video images streamed from the video camera, the objects are alsowithin the field of view of the camera unit 36. Video images from thevideo camera can be streamed to the displays 28, 29 during any of thesteps in FIG. 5.

In step 112, while the displays 28, 29 show a window 113 with videoimages streaming from the video camera in the window 113, theinstructions provided on the displays 28, 29 may also include writteninstructions stating to the surgical personnel to place the patientwithin the window 113. This is illustrated in FIG. 5C. The window 113may also show where certain edges or sides of the operating table are tobe located by overlaying geometric visual aids (such as cross-hairs,edge lines, etc.) onto the video images and providing accompanyingwritten instructions. Once the patient is located within the window andthe operating table is properly aligned, the patient is positionedaccording to the pre-operative plan and/or other procedure information.Once the patient is in the proper position, transition to step 114 mayrequire input from the surgical personnel, such as selecting “OK” or“DONE” on the displays 28, 29 with an input device to indicate to the ORSetup module 109 that the patient is in position.

Tracker placement is performed in step 114. One exemplary embodiment ofinstructions provided by the guidance station 20 for placing thetrackers 44, 46 is shown in FIG. 8. To begin, in step 120,representations of the femur F and tibia T are shown on the displays 28,29 with desired tracker placement and associated instructions. Anexample of this is shown in FIG. 5D. Generic bone representations areused to generally show proper placement based on distance from the kneejoint, for example, or distances from certain anatomical landmarksassociated with the knee joint (e.g., distances from patella, tibialtubercle, etc.). Written instructions on the displays 28, 29 canindicate distances from the anatomical landmarks to each of the trackers44, 46 (distances may be indicated from landmark to the base of eachtracker 44, 46 mounted to bone). A desired distance between trackers 44,46 (or the bases thereof) may also be numerically and visually depictedon the displays 28, 29. In some embodiments, the instructions on thedisplay 28, 29 include written instructions on the placement of the legin a leg holder prior to placing the trackers 44, 46 and instructions onsecuring the leg holder in position. One such leg holder is shown inU.S. patent application Ser. No. 13/554,010, entitled, “Multi-positionLimb Holder”, published as U.S. Patent Application Publication No.2013/0019883, hereby incorporated by reference.

The video camera described above may be integrated into a machine visionsystem of the guidance station 20 with ability to identify the leg ofthe patient using conventional machine vision technology. Referring toFIG. 5E, once the leg is identified and shown in the window 113 on thedisplays 28, 29, the guidance station 20 overlays desired positions ofthe trackers 44, 46 on the displays 28, 29 (shown by arrows), whilesimultaneously and continuously showing the video images from the videocamera, which shows the surgeon and/or surgical personnel placing thetrackers 44, 46 (actual trackers not shown in FIG. 5E).

The surgical personnel position the trackers 44, 46 in step 122. Thismay include placing bone pins and attaching the trackers 44, 46 to thebone pins, or this may include making an incision at the knee jointusing manual instruments to gain access to the joint and mounting a boneplate and coupling tracking elements of the trackers 44, 46 to the boneplate such as shown in U.S. Provisional Patent Application No.61/753,219, filed on Jan. 16, 2013, entitled, “Tracking Devices andNavigation Systems and Methods for Use Thereof”, hereby incorporated byreference. Once in position, the camera unit 36 is activated to beginreceiving position-related signals from the LEDs 50, of the trackers 44,46.

In step 124, the navigation computer 26 measures distances between theLEDs 50 on tracker 44 with the LEDs 50 on tracker 46. This provides abasic indication of how far apart the trackers 44, 46 are located on thebones, e.g., femur and tibia. In one embodiment, a shortest distancebetween the closest two LEDs 50 and a farthest distance between thefarthest two LEDs 50 are measured. In step 126 these measure distancesare compared to a predetermined range of distances. If both of theshortest and farthest measured distances fall within the range, themethod proceeds to step 128. If not, the method goes back to step 120and the trackers 44, 46 are repositioned according to the instructionsin step 120. If the method goes back to step 120, the instructions canadditionally include details on whether the trackers 44, 46 were tooclose together or too far apart—giving the surgical personnel additionalguidance on where to position the trackers 44, 46. Repositioning of thetrackers 44, 46 may simply require adjustment of the trackers 44, 46about one or more adjustable degrees of freedom without requiringremoval of the base (or bone pins) from the bone. In extreme cases, thetrackers 44, 46 will need to be completely removed from the bone andre-mounted.

Once the trackers 44, 46 have been positioned within the predeterminedrange of distances, then the trackers 44, 46 are registered to theanatomy. Registration of bone surfaces and reference landmarks iswell-known in the art using pointers P and will not be described indetail. Registration results in the pre-operative MRI or CT images beingassociated with positions of the LEDs 50 on the trackers 44, 46. As aresult, movement of the femur F and tibia T can be tracked by trackingmovement of the LEDs 50.

Once the positions and orientations of the femur F and tibia T areregistered to the LEDs 50, the navigation computer 26 can simulatemovement of the femur F and tibia T through a range of motion fromflexion to extension and in all anticipated positions of the femur andtibia during the surgical procedure. For instance, the procedure mayrequire the knee to be placed in maximum flexion and extension. Thenavigation processor 52 can simulate where the LEDs 50 will be locatedat maximum flexion and extension positions of the leg and determinewhether the LEDs 50 will be within the field-of-view of each of thesensors 40 in all of these positions since the field-of-view of thesensors 40 is also known to the navigation computer 26. In other words,the navigation computer 26 can simulate movement of the femur F andtibia T during the procedure and detect whether any of the LEDs 50 willbe blocked from the field-of-view of any of the sensors 40.

Alternatively, as opposed to running the simulation, the instructions onthe displays 28, 29 may require the surgical personnel to actually movethe leg through maximum extension and flexion in the leg holder, whilethe guidance station 20 tracks the LEDs 50 on the trackers 44, 46.Blockage is then identified by determining if at any position of theleg, any of the LEDs 50 is blocked from transmitting signals to thesensors 40.

If blockage is predicted in the simulation or actually detected whenmoving the leg, then the method proceeds to step 134. In step 134,representations of the actual bones of the patient are shown on thedisplays 28, 29 along with the current tracker placement and the desiredtracker placement (similar to FIG. 5E, but now using navigation positioninformation). Instructions for moving or repositioning the trackers 44,46 are also displayed on displays 28, 29. In some cases, repositioningmay simply require sliding, tilting or rotating a head of one of thetrackers 44, 46 using adjustment features of the trackers 44, 46,without requiring complete removal of the trackers 44, 46 from the bone.See, for example, adjustment features of the trackers shown in U.S.Provisional Patent Application No. 61/753,219, filed on Jan. 16, 2013,entitled, “Tracking Devices and Navigation Systems and Methods for UseThereof”, hereby incorporated by reference. In other cases, one or bothof the trackers 44, 46 need to be removed from the bones.

Once repositioned, the initial error check in step 124 is performedagain. If the error is acceptable, then the trackers 44, 46 arere-registered to the anatomy and the remaining steps continue as before.At step 132, if no blockage is predicted or detected, the methodproceeds to step 116. Transition to step 116 may be automatic after thesimulations or movements are performed in step 132, or transition tostep 116 may require input from the surgical personnel, such asselecting “OK” or “DONE” on the displays 28, 29 with an input device toindicate to the OR Setup module 109 that the patient is in position.

Prior to step 114, the trackers 44, 46 may be setup according to theprocedure outlined in U.S. Provisional Patent Application No.61/753,219, filed on Jan. 16, 2013, entitled, “Tracking Devices andNavigation Systems and Methods for Use Thereof”, hereby incorporated byreference, which may improve the likelihood that the trackers 44, 46 donot require repositioning during positioning in step 114.

The surgeon also has the ability to again review the design, confirm itmatches the patient, and either give final approval or makes revisionsin implant size, position, and/or orientation.

Instructions for placement of the machining station 56 are provided instep 116. One example of how these instructions are provided is shown insteps 136 through 142 in FIG. 9. Once the camera unit 36, patient, andtrackers 44, 46 are properly positioned, the guidance station 20 canassist in guiding the machining station 56 into position relative to thebones to be machined. In step 136, the desired placement of themachining station 56 is shown on displays 28, 29. The cart 57 of themachining station 56 also has an integrated display 59 which is incommunication with the guidance station 20 (see FIG. 1). The machiningstation display 59 additionally shows the desired placement of themachining station 56. The desired placement may be an overhead visualillustration of the cart 57 in a desired position, such as shown inFIGS. 6 and 7.

A position and orientation of the cart 57 is tracked by the guidancestation 20 using the instrument tracker 48. More specifically, owing torigid connections of the instrument tracker 48 to the end effector andthe end effector to an arm/coupler structure of the machining station56, the guidance station 20 is able to determine a position andorientation of the cart 57 based on the position and orientation of theinstrument tracker 48 using: (1) joint angle data measured by positionencoders located at joints in the machining station 56 and/or jointangle data calculated by a kinematics module, as described in U.S.Provisional Patent Application No. 61/679,258, entitled, “SurgicalManipulator Capable of Controlling a Surgical Instrument in either aSemi-Autonomous Mode or a Manual, Boundary Constrained Mode”, thedisclosure of which is hereby incorporated by reference; and (2) datarelating to the arm/coupler structure (e.g., virtual model data) of themachining station 56, as described in U.S. Provisional PatentApplication No. 61/679,258, entitled, “Surgical Manipulator Capable ofControlling a Surgical Instrument in either a Semi-Autonomous Mode or aManual, Boundary Constrained Mode”, the disclosure of which is herebyincorporated by reference. Alternatively, a separate tracker (not shown)is attached to and calibrated to a virtual model of the cart 57 to tracka position and orientation of the cart 57.

In either case, the displays 28, 29, 59 in some embodiments not onlyshow the desired overhead position of the cart 57, but also the currentposition of the cart 57. One example of representations of the cart 57shown on displays 28, 29, 59 is shown FIG. 9A. In FIG. 9A, one visualrepresentation is an image of the cart 57 (represented by a 2-Drectangle) shown in the desired position. Another visual representationis an image of the cart 57 (represented by a 2-D rectangle) shown in thecurrent position. The representation of the cart 57 in the currentposition moves on the displays 28, 29, 59 as the cart 57 is moved.Further instructions provided by the guidance station 20 may includegeometric images, such as an arrow, guiding the surgical personnel as tothe direction in which to move the cart 57 to reach the desiredposition.

In step 138, the surgical personnel place the machining station 56 inthe desired position by watching the displays 28, 29, 59, and moving thecart 57 such that the visual representations on the displays 28, 29, 59of the actual cart position moves toward the visual representation ofthe desired position. In step 140, the OR Setup module 109 checks theerror between actual position and desired position until the cart 57reaches the desired position. Once the actual position of the machiningstation 56 is within a predetermined tolerance of the desired position,as depicted by the visual representation of the actual position of thecart 57 being aligned with the visual representation of the desiredposition of the cart 57, i.e., the rectangles are aligned, the OR Setupmodule 109 indicates that the machining station 56 is in the desiredposition and moves to step 118. The visual images on the displays 28,29, 59 may blink or provide some other visual effect when the cart 57has reached the desired position.

In step 118, the guidance station 20 instructs the surgical personnel ontheir proper positions relative to the patient, machining station 56,guidance station 20, etc. This may be done by re-displaying the overheadlayout, such as those shown in FIGS. 6 and 7. Once the surgicalpersonnel are in position and ready, the procedure can be started—seestep 106 in FIG. 4.

In some embodiments, the machining station 56 is a robotic surgicalcutting system for cutting away material from a patient's anatomy, suchas bone or soft tissue. Once the cutting system is determined to be inthe proper position by the guidance station 20, the cutting system cutsaway material to be replaced by surgical implants such as hip and kneeimplants, including unicompartmental, bicompartmental, or total kneeimplants. Some of these types of implants are shown in U.S. patentapplication Ser. No. 13/530,927, entitled, “Prosthetic Implant andMethod of Implantation”, the disclosure of which is hereby incorporatedby reference. The guidance station 20 instructs the surgeon on properprocedures for locating these implants on bone and securing the implantsin position, including the use of trial implants.

In other systems, the instrument 22 has a cutting tool that is movablein three degrees of freedom relative to a handheld housing and ismanually positioned by the hand of the surgeon, without the aid ofcutting jigs, guide arms or other constraining mechanism. Such systemsare shown in U.S. patent application Ser. No. 13/600,888, entitled,“Surgical Instrument Including Housing, a Cutting Accessory that Extendsfrom the Housing and Actuators that Establish the Position of theCutting Accessory Relative to the Housing”, the disclosure of which ishereby incorporated by reference.

In these embodiments, the system includes a hand held surgical cuttinginstrument having a cutting tool. A control system controls movement ofthe cutting tool in at least 3 degrees of freedom using internalactuators/motors, as shown in U.S. patent application Ser. No.13/600,888, entitled, “Surgical Instrument Including Housing, a CuttingAccessory that Extends from the Housing and Actuators that Establish thePosition of the Cutting Accessory Relative to the Housing”, thedisclosure of which is hereby incorporated by reference. The guidancestation 20 communicates with the control system. One tracker (such astracker 48) is mounted to the instrument. Other trackers (such astrackers 44, 46) are mounted to a patient's anatomy.

In this embodiment, the guidance station 20 communicates with thecontrol system of the hand held surgical cutting instrument. Theguidance station 20 communicates position and/or orientation data to thecontrol system. The position and/or orientation data is indicative of aposition and/or orientation of the instrument 22 relative to theanatomy. This communication provides closed loop control to controlcutting of the anatomy such that the cutting occurs within a predefinedboundary (the term predefined boundary is understood to includepredefined trajectory, volume, line, other shapes or geometric forms,and the like).

In alternative embodiments the trackers 44, 46, 48 could be otherline-of-sight tracking devices or non-line-of-sight tracking devicesused for navigation. The trackers 44, 46, 48 could employ sound waves,magnetic fields, RF signals, and the like to determine position and/ororientation. In some of these embodiments, step 110 relates to placementof sensing devices, transmitters, generators, etc. associated with theseother types of navigation systems. Likewise, steps 130 and 132 relate tochecking for obstructions or other interference with signals from theseother types of navigation systems. In essence, surgical personnel areinstructed to place trackers of the navigation system with respect tothe patient's anatomy, regardless of the type of navigation employed, sothat obstructions or interference is minimized or within acceptabletolerances.

In some embodiments, the objects may be arranged with respect to anoperating room table that is fixed in the operating room, i.e., unableto be readily moved, except for adjustments of portions of the operatingroom table. In some embodiments, some or all of the objects to bearranged according to their desired placement may be located outside theoperating room and first need to be moved into the operating room. Inother embodiments, some or all of the objects to be arranged accordingto their desired placement may already be located inside the operatingroom, but not yet in their desired placements.

In some embodiments, pre-surgery is considered the time leading up toany cutting or incision of the patient in the operating room forpurposes of treatment. Such cutting may include the cutting of skin andtissue to access the knee joint for purposes of knee replacement or thehip joint for purposes of hip replacement.

In some embodiments, arranging the objects in the operating room may beperformed manually such as by pushing a wheeled cart of the object intoposition, or manually attaching trackers to the patient. In otherembodiments, arranging the objects may include guiding the objects intotheir desired placement remotely or by some automated control, such asby moving an automated cart using associated steering controls.

Several embodiments have been discussed in the foregoing description.However, the embodiments discussed herein are not intended to beexhaustive or limit the invention to any particular form. Theterminology which has been used is intended to be in the nature of wordsof description rather than of limitation. Many modifications andvariations are possible in light of the above teachings and theinvention may be practiced otherwise than as specifically described.

What is claimed is:
 1. A system for arranging a mobile cart of a roboticsystem in an operating room according to surgical procedure information,the robotic system having a tracking device, said system comprising: alocalizer configured to track the tracking device of the robotic systemto determine a current placement of the mobile cart; a guidance stationcoupled to the localizer and being configured to receive the surgicalprocedure information, evaluate the surgical procedure information, andto determine a desired placement of the mobile cart of the roboticsystem in the operating room based on the evaluation of the surgicalprocedure information; and a display configured to display visualrepresentations of the current placement and the desired placement ofthe mobile cart to guide a user on manual placement of the mobile cartin the operating room.
 2. The system as set forth in claim 1, whereinthe display is of the guidance station.
 3. The system as set forth inclaim 1, wherein the desired placement of the robotic system comprisesan overhead visual illustration of the robotic system.
 4. The system asset forth in claim 1, including generating a visual effect when therobotic system has reached the desired placement.
 5. The system as setforth in claim 1, wherein the robotic system is a robotic surgicalcutting system and is configured to cut away material from a patient'sanatomy.
 6. The system as set forth in claim 1, wherein the surgicalprocedure includes an identification of a bone to be treated and anidentification of a desired implant to be attached to the bone.
 7. Thesystem as set forth in claim 1, wherein the robotic system is capable ofcommunication with the guidance station.
 8. The system as set forth inclaim 1, wherein a tracking device is coupled to a base of the roboticsystem to track movement of the robotic system.
 9. The system as setforth in claim 1, wherein guiding a user on manual placement of themobile cart in the operating room further includes guiding the user asto a direction in which to move the mobile cart in the operating room.10. The system as set forth in claim 1, wherein providing the surgicalprocedure information to the guidance station includes providing patientinformation to the guidance station.
 11. The system as set forth inclaim 1, wherein providing the surgical procedure information to theguidance station includes providing surgeon preferences to the guidancestation.